Motorized window shade system

ABSTRACT

An elongated reelable shade, first and second spaced support brackets removably connected to first and second and opposite ends of said elongated reelable shade for supporting said reelable shade from a fixed support, an electrical drive motor having an output shaft for rotating said elongated reelable shade around its axis to selectively reel and unreel said shade, an electrical circuit for energizing and operating said motor, the electrical circuit including a controller coupled to and controlling the operation of said drive motor, and a coupler for removably coupling said output shaft of said motor to said first end of said elongated reelable shade, a single housing having said first bracket fixed thereto, said single housing containing and supporting said motor, said electrical circuit and said coupler, said coupler comprising an output driver which removably receives said first end of said shade with rotatable driving relationship.

This is a division of application Ser. No. 08/773,184, filed Dec. 27,1996, now U.S. Pat. No. 5,848,634.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to motor operated window shade systems.More particularly, the present invention relates to a motor drivenwindow shade system incorporating a slim design housing for mountingadjacent a window jamb and which includes a circuit to control theoperation of the drive motor and the motor itself. Even moreparticularly, the invention relates to a microprocessor controlledmotorized window shade system. Furthermore, the invention relates to amotor operated window shade system that allows retrofitting of manualshades or which can be used with shades specially designed for use withmotorized systems.

A conventional reelable window shade is well known. The shade can bemoved manually up or down in front of a window to control e.g., thelight level, temperature, air flow, or to provide privacy. The knownreelable shade is fairly inexpensive and is easy to install. If theshade is damaged, a new shade can be replaced very easily. These typesof shades are sold in retail stores and do-it-yourself centers acrossthe U.S. The shades are typically stocked in 3, 4, 5 and 6 foot widths.The shade can easily be cut to the proper width with a cutting deviceeither at the point of sale or at installation time. The installer canmeasure and install the shade on the same site visit.

The conventional reelable shade has a first pin end and a second springend with a rectangular barb extending outwardly. The pin end is insertedinto a circular hole in a bracket. The spring end is mounted in asimilar shaped bracket with a slot designed to keep the barb fromrotating. The brackets are designed to be mounted inside a window framei.e., inside the jamb, or along the outside of a window frame. The userpulls the reelable shade down by a hem bar located along the bottom edgeof the shade until the desired amount of shade material is showing. Theuser then eases up on the hem bar until the pawl mechanism in the springend of the shade locks the shade into position. As the shade is beingpulled down, the spring is being wound up.

When the user wants to put the shade up, the user pulls down on the hembar slightly to disengage the pawl mechanism and then guides the hem barupward as the spring pulls the fabric upward. If the user lets go of theshade as the shade is travelling upward the spring in the shade willcause the shade to travel upward out of control. The hem bar willcontinue to rotate around the roller until it stops. The setting ofmultiple shades at the same relative position can be a very timeconsuming process.

The known shades are not capable of receiving inputs from time clocks,photo sensors, occupant sensors or infrared hand held transmitters.

It is known to make a window covering from a plurality of diverse panelswhich can be moved selectively in front of a window to control the lightlevel, temperature or air flow, or to provide privacy. Such a system isdescribed in U.S. Pat. No. 5,467,266 entitled "Motor Operated WindowCover." It is commonly owned by Lutron Electronics, Inc., the owner ofthe present application. This system has an upper and a lower roller.The motor is located in the upper roller and a spring is located in thelower roller. The system allows the user to choose different fabrics,colors and sun blocking materials to be combined together to form aseries of different panels. The fabric is wound or unwound onto eitherthe upper or lower roller to display the different panels. The differentpanels can be recalled at the touch of a button. Each shade is made toorder which can result in a long lead time. The two rollers and fabricare sold as a unit. If the unit ever fails, the unit must be returned tothe manufacturer or a technician must visit the job site.

Installation of these systems often requires a skilled craftsman. Theinstaller usually will need to make one visit to measure the window andanother separate visit to install the system.

The hem bar located at the bottom of the shade travels in channelssecured to the sides of the window opening, thus decreasing the amountof light that can enter through the window when the shade is up. Themotor is connected to a nearby power source with line voltage wiring.

These systems according to U.S. Pat. No. 5,467,266 are capable ofreceiving inputs from time clocks, photo sensors, and occupant sensors.They are also capable of receiving inputs from infrared hand heldtransmitters through accessory devices. Multiple units are capable ofworking together as a system.

A single motorized roller shade is made by Somfy of Cluses, France. Theroller is secured to the window opening with two mounting brackets. Thesingle roller shade is custom made with a fabric of choice. The motor isinstalled inside the roller tube at the factory and line or low voltagewiring connects the motor to a nearby power source. The unit is notcapable of receiving inputs from time clocks, photo sensors or occupantsensors. If the unit ever fails, the unit must be returned to themanufacturer or a technician must visit the job site.

Another system, the Makita Automatic Drapery Opener System is designedto open and close standard drapes. Line voltage wiring connects the unitto a nearby power source. The units have dedicated input and outputjacks for connection between multiple units and wall controls. Multipleunits can be grouped together although different mother and daughterunits are required. One mother unit can be wired to two daughter unitsusing standard phone cables which have crossed wires. The unit will notwork properly if non standard straight-through wiring telephone typecables are used to connect the units. Splitters are required when usingboth timers and wall switches. When using more than one system per room,multiple frequency transmitters are required to control each shadeindependently. The infrared sensor is approximately 1"×1" in size andblack and white in color. This makes the sensor difficult to locate infront of the window dressing without detracting from the look whilestill allowing the sensor to work properly.

These units are capable of receiving inputs from timers and infraredhand held transmitters. They can not accept inputs from occupant sensorsand photo sensors.

A number of patents for motor driven window treatments are known. Forexample, U.S. Pat. No. 5,540,269 to Plumer discloses a motor drivenroller blind. This system uses a means provided alongside the windowcapable of providing an electrical signal representative of the movementof the roller blind.

U.S. Pat. No. 5,414,334 to Cheron discloses a control device for anasynchronous roller blind motor. This patent is assigned to Somfy ofCluses, France.

U.S. Pat. No. 5,372,173 to Horner discloses a window having motorizedshades. The mechanism described in this patent utilizes separate motorswith belt driven pulleys and does not provide a neat and simpleinstallation.

U.S. Pat. No. 5,351,743 to Jackson discloses a roller shutter assemblyintended for use as a garage door.

Although not relating to window shades, U.S. Pat. No. 5,303,972 toHeider et al. discloses a remote control for a rectangular box topclosure including a tarpaulin. This device is used to enclose the top ofa rectangular enclosure, for example, the top of a trailer truck.

U.S. Pat. No. 5,249,616 to Yen discloses a double layer window withshade roller units for regulating light. This system utilizes reversiblemotors provided at the bottom or bottom and top of the window openingand does not provide a simple and convenient installation.

U.S. Pat. No. 5,198,974 to Orsat discloses a safety device for amotorized roller shutter comprising means supplying an electrical signalrepresenting the displacement of the rolling shutter. The systemcomprises a pulley on which is wound a flexible element whose free endis connected to the end of the rolling shutter such that the unrollingof the rolling shutter causes the unrolling of the flexible element.

U.S. Pat. No. 5,105,871 to Baud et al. discloses a tubular motor windingdevice for a blind, roller shutters or the like. The winding devicecomprises a winding tube inside of which is a tubular motor.

U.S. Pat. No. 5,088,543 to Bilbrey discloses a skylight shade whichutilizes a motor winding a cord that moves the window shade to adjustthe skylight opening.

U.S. Pat. No. 5,044,417 to Bresson discloses a roller assembly forautomatically winding and unwinding closures such as blinds, shades andsimilar devices in which the drive mechanism and all the accessoriesthereof are housed inside the drum on which the shade is wound.

U.S. Pat. No. 5,042,866 to Cody discloses an automotive sunscreen forthe windshield of an automobile.

U.S. Pat. No. 5,038,087 to Archer et al. discloses an apparatus forcontrolling window blinds and awnings wherein the drive motor is locatedwithin the shade spool or within a horizontal element disposed above theshade element.

U.S. Pat. No. 4,951,730 to Hsu discloses a window blind systemcomprising a member which is mounted horizontally above the windowopening and having means at each end for holding the window blinds inposition.

U.S. Patent No, 4,766,941 to Sloop et al. discloses a window shade withselectively variable shading characteristics.

U.S. Pat. No. 4,712,104 to Kobayashi discloses a remote control blindsystem wherein the blind includes rotatable slats.

U.S. Pat. No. 4,683,932 to Bubendorff discloses a rolling shutter of thetype comprising a first shaft for winding and/or unwinding a sectionalstructure consisting of blades provided with catch means adapted to beengaged by driving means mounted on and rotatable with a second shaftlocated downstream of the winding shaft and mounted in lateral flangesof the shutter housing with guide rails slidably engaged by the sideends of the shutter blades.

U.S. Pat. No. 4,665,965 to Pasquier et al. discloses a control systemfor roller blinds or the like with swivel blades.

U.S. Pat. No. 4,444,363 to Jacquel et al., and assigned to Somfy ofCluses France, discloses a device for driving a flexible protection webrolled up on a shaft. The device includes two shafts at either end ofthe flexible protection web.

U.S. Pat. No. 4,417,185 to Bullat assigned to Somfy discloses a drivingsystem for roll-up shades, blinds, rolling shutters and the like.

U.S. Pat. No. 4,411,348 to Fillion assigned to Somfy discloses a controldevice for an electric motor reducing unit of the type intended fordriving a winding rod, drum or tubular coil, a rolling shutter, rollerblinds or the like.

U.S. Pat. No. 4,372,367 to Baldanello et al. discloses a roller blindincluding a reversible electric motor disposed in the winding roller ofthe roller blind.

U.S. Pat. No. 4,347,886 to Von Knorring discloses a roller blind havinga motor which engages with the window blind to raise and lower the blindand such that when the blind is lowered, the blind moves closer to thewindow frame and when it is raised it moves further away from the windowframe.

U.S. Pat. No. 4,042,028 to Ennes et al. discloses an adjustable tubeshade roller which can be operated by an electric motor.

U.S. Pat. No. 1,795,745 to Twiss discloses a remote control having anelectrical actuating mechanism for operating a window shade.

U.S. Pat. No. 3,337,992 to Tolson discloses remotely controlled closuressuch as windows, doors and the like which can be operated from one ormore remotely located sensing devices.

The devices described in the above patents suffer from at least one of anumber of disadvantages including inability to communicate with otherdevices, lack of intelligent control, e.g. by a microprocessor, and thushaving inability to be programmed easily, bulky size causing difficultyin installation, an unattractive appearance and maintenance problems aswell as inability to easily retrofit to existing manually actuatedshades.

There is, thus, a need for a small, easy to install, attractive, singleunit, intelligent device for controlling the motorized operation ofwindow shades.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a motorized windowshade system that is simple to install.

It is also an object of the present invention to provide a motorizedwindow shade system that is neat and attractive in appearance and whichdoes not intrude into the window opening area.

It is yet still a further object of the present invention to provide amotorized window shade system that is mechanically simple and thusreliable.

It is yet still another object of the present invention to provide amotorized window shade system that is microprocessor controlled andeasily programmed by a user to set desired upper position and lowerposition limit values.

It is yet still a further object of the invention to provide a motorizedwindow shade system that can be connected with other units to allowcontrol of a plurality of motorized window shade units in a predefinedsynchronism.

It is yet still another object of the invention to provide a motorizedwindow shade system that can be used with remote control devices and/orwall mounted controls.

It is still yet a further object of the invention to provide a motorizedwindow shade system that utilizes modular telephone wires forinterconnection with other window shade units and that is polarityinsensitive so that it will operate with cross-pinned orstraight-through type telephone wires, thus simplifying installation.

It is yet still a further object of the invention to provide a motorizedwindow shade system that can be retrofitted to existing manuallyactuated shades.

The above and other objects are achieved by a combination comprising anelongated reelable shade having first and second opposite ends, firstand second spaced support brackets, the second bracket being removablyconnected to the second end of said elongated reelable shade forsupporting said reelable shade from a fixed support, an electrical drivemotor having an output shaft for rotating said elongated reelable shadearound its axis to selectively reel and unreel said shade, an electricalcircuit for energizing and operating said motor, the electrical circuitincluding a controller coupled to and controlling the operation of saidmotor, and a coupler for removably coupling said output shaft of saidmotor to said first end of said elongated reelable shade, a singlehousing having said first bracket fixed thereto, said single housingcontaining and supporting said motor, said electrical circuit and saidcoupler, said coupler removably receiving said first end of said shadewith rotatable driving relationship.

The invention further encompasses an elongated reelable window shadeadapted for motor operation by an external motor drive; said shadecomprising an elongated rigid tubular barrel having an elongated shadereeled thereon; one end of said barrel having a drive coupler isconnected thereto for removable connection to a motor drive; theopposite end of said barrel containing an interior elongated torsionspring having an exterior rectangular barb connector for connection tothe slot of a conventional shade mounting bracket; and a circular pinwith a low friction outer surface and having a slot in one end surfacethereof which is force-fitted onto the end of said barb; said circularpin being coaxial with said barrel and said spring.

The invention also encompasses a control switch for determining at leastone of the reeling end limits of a reelable shade by being operated whenan end limit is reached; said control switch including a switch, apivotally mounted shade rise limit lever arm; said shade rise limitlever arm having end disposed adjacent the path of movement of saidshade; a free end of said shade having an enlarged hem liner along itsedge whereby, when said hem liner at the free end of said shade reachesand contacts said end of said rise limit lever arm, said rise limitlever arm is rotated to operate said switch to indicate that said shadehas been fully reeled to an end limit.

Another embodiment of the invention includes a control switch fordetermining at least one of the end limits of a reelable shade by beingoperated when an end limit is reached; said control switch including aswitch, a pivotally mounted shade lower limit lever arm; said shadelower limit lever arm having an end disposed adjacent to but spaced fromthe outer periphery of said reelable shade and being removed from thepath of said shade when said shade is being unreeled from over one sideof the shade reel, but being disposed in the path of said shade aftersaid shade has been fully unreeled and when continuous unreeling causessaid shade to reel in an opposite direction over the shade reel, therebyto activate said switch to indicate that a fully unreeled position ofsaid shade has been reached.

The invention is also directed to a unitary bracket and motor drive foran elongated reelable shade; said motor drive comprising a reversible DCmotor, a DC power source therefor, a control circuit for coupling saidDC power source and said motor, a microprocessor for controlling thesequence and operation of said motor, a motor operation sensor coupledto said microprocessor, and an input control signal sensor connected tosaid microprocessor; a gear reduction train assembly having an inputshaft end connected to the output shaft of said motor and an outputshaft end connected to an output drive shaft which is connectable to oneend of said shade; and a unitary housing for enclosing said motor, DCsource, control circuit, microprocessor, motor operation sensor, andgear reduction train; said bracket being fastened to said unitaryhousing.

The invention also encompasses novel processes including a process ofinstalling a motor-operated window shade comprising the steps of fixinga pin in a first end of said shade, fixing a connector socket in asecond end of said shade, fixing a first bracket to a shade supportsurface for rotatably receiving said first end of said shade, fixing asecond bracket carrying a motor driven shaft stub in a location spacedfrom said first bracket, inserting said motor driven shaft stub intosaid connector socket and inserting said pin for rotation in said firstbracket.

Also included is a process of retrofitting with a motor operatedmechanism, a reelable window shade of the type having a pin end and aspring mounted barb end, the process comprising the steps of fixing asecond pin to the barb end of said shade, replacing said pin of saidshade with a connector socket, fixing a first bracket to a shade supportsurface for rotatably receiving said second pin attached to said barbend of said shade, fixing a second bracket carrying a motor driven shaftstub in a location spaced from said first bracket, inserting said motordriven shaft stub into said connector socket and inserting said secondpin for rotation in said first bracket.

The invention includes the combination of a plurality of spaced reelableshades, a plurality of reversible drive motors separate from andconnected to one end of respective ones of each of said shades, acontrol circuit for operating each of said drive motors from a commonpower source; and a communication circuit for interconnecting each ofsaid control circuits to operate each of said plurality of reversiblemotors so that their respective shades are reeled and unreeled in apredetermined synchronism with one another; a respective unitary housingfor each of said reversible drive motors and their respective controlcircuits; each of said housings containing at least first and secondfour-wire jacks coupled to their respective communication circuit; eachsaid four-wire jacks having first, second, third and fourth lateralconnectors disposed side by side and extending therefrom wherein theapplication of a signal connecting the first and second or third andfourth connectors causes the drive of said motor in a first directionand the application of a signal connecting said first and third or saidsecond and fourth connectors causes the drive of said motor in anopposite direction; a four-wire cable connected from a four-wire jack ofa first of said jacks in a first of said housings to a four-wire jack ofa first of said jacks in a second of said housings; the connection ofsaid four wire cable being polarity insensitive.

A further embodiment of the invention is directed to a communicationcircuit for supplying at least two control signals to a control circuit,the control circuit controlling the state of operation of a controlleddevice, the communication circuit including at least one communicationport, the communication port containing a plurality of connectorsdisposed side-by-side, the communication circuit being polarityinsensitive so that the connection of selected ones of said connectorsin pairs will control said control circuit to operate said controlleddevice in a predetermined manner even if a cable containing linescoupled to respective ones of said connectors has cross-pinned wires.

Yet another embodiment of the invention includes an apparatus forcontrolling operation of a motorized window shade, the apparatuscomprising a drive circuit for driving an electric motor operating thewindow shade; a control circuit for controlling the operation of saiddrive circuit, said control circuit including a microprocessor, themicroprocessor being coupled to first and second switches for enablingdriving of the electric motor in respective first and second directionscorresponding to upward and downward movement of the window shade, andfurther comprising a program switch, the microprocessor of the controlcircuit being programmed to allow setting of the upper and lower limitsof travel of said window shade, said microprocessor being programmedwith a program whereby to set a first of said limits of travel, thewindow shade is adjusted to a desired upper or lower level limitposition using at least one of said first and second switches, saidprogram switch is then actuated followed by the actuation of one of saidfirst and second switches to set a first of said limits; said windowshade is then adjusted to a desired position for a second of said limitsusing at least one of said first and second switches; said programswitch is again actuated, and the other of said first and secondswitches is actuated to set said second of said limits.

Presented below are further definitions of the invention, which are setforth in separate paragraphs. These inventions include:

A. A method for setting upper and lower limits of travel of a motorizedwindow shade, the motorized window shade having a control circuitincluding a microprocessor for controlling the direction of movement ofthe window shade and having a first switch for allowing control of thewindow shade in an upward direction, a second switch for allowingcontrol of the window shade in a downward direction and a program switchfor enabling setting of the limits, the method comprising: adjusting theshade to a desired upper limit position using at least one of said firstand second switches; actuating said program switch to command saidmicroprocessor to a program mode; thereafter actuating said first switchcontrolling upward movement of said window shade to set the upper limitposition to the current shade position; adjusting the window shade to adesired lower level position using at least one of said first and secondswitches; actuating said program switch to command said microprocessorto said program mode; and thereafter actuating said second switchcontrolling downward movement of said window shade to set said lowerlimit to the current position of the window shade.

B. Apparatus for detecting if a reelable window shade of a motorizedwindow shade control system has exceeded a preset upper limit level forthe window shade, the apparatus comprising a drive circuit for drivingan electric motor controlling upward and downward movement of the windowshade; a control circuit including a microprocessor for controlling theoperation of said drive circuit; a switch actuated by movement of saidwindow shade when said window shade moves upwardly past a desired upperlevel limit of said window shade; said microprocessor comprising aprogram operating in response to a change of state of said switch whensaid window shade is traveling upward so as to:

stop the operation of said drive motor;

reverse the direction of said drive motor;

set a counter of said control circuit when said switch again changesstate to a preset number corresponding to a home position of said windowshade; and

thereafter stop said motor when said window shade reaches a preset upperlimit.

C. A process for detecting when a window shade of a motorized windowshade system has exceeded an upper limit level, the window shade systemincluding a drive circuit controlling an electric motor driving thewindow shade in upward and downward directions, a control circuitincluding a programmed microprocessor controlling the operation of saiddrive circuit and a switch activated when said window shade is travelingupwardly, the method comprising the steps of: changing the state of saidswitch when said shade is traveling upwardly and has exceeded the upperlimit level; stopping said drive motor; reversing the direction of saidmotor so that said window shade travels downwardly; setting a counter insaid control circuit when said switch again changes state as said windowshade is traveling downwardly; and thereafter stopping said motor whensaid shade reaches the upper limit.

D. Apparatus for detecting when a window shade of a motorized windowshade system has reached full downward extension and is beginning towrap around a reel for said window shade in an opposite direction to adesired direction of wrap around the reel, the motorized window shadesystem comprising a drive circuit for driving an electric motor thatmoves the shade in upward and downward directions, a control circuitcontrolling the operation of said drive circuit and having a programmedmicroprocessor and a switch actuated by said window shade as said windowshade is traveling downwardly and then begin to wrap around the reel inthe opposite direction, the programmed microprocessor being programmedto detect the change of state of said switch by said window shade assaid window shade is traveling downwardly, the programmed microprocessorbeing programmed to:

respond to the change of state of said switch so as to stop said motor;

reverse the direction of said motor so that said window shade travelsupwardly changing the state of the switch until said window shade isfully wrapped around the window shade reel and another change of stateof said switch by said shade occurs;

stop said motor again;

again reverse the motor direction so that said window shade travelsdownwardly;

set a counter of said control circuit to a preset number correspondingto a home position of said window shade when a change of state of saidswitch again occurs; and

stop said motor when said shade reaches a preset upper limit.

E. A method for detecting when a window shade of a motorized windowshade system has reached full downward extension and is beginning towrap around a reel for said window shade in an opposite direction to adesired direction of wrap around the reel, the motorized window shadesystem comprising a drive circuit for driving an electric motor thatmoves the shade in upward and downward directions, a control circuitcontrolling the operation of said drive circuit and having a programmedmicroprocessor and a switch actuated by said window shade as said windowshade is traveling downwardly and then begins to wrap around the reel inthe opposite direction, the programmed microprocessor being programmedto detect the change of state of said switch by said window shade assaid window shade is traveling downwardly, the programmed microprocessorbeing programmed to respond to the change of state of said switch, themethod comprising:

stopping said motor in response to actuation of said switch;

reversing the direction of said motor so that said window shade travelsupwardly changing the state of the switch until said window shade isfully wrapped around the window shade reel and another change of stateof said switch by said shade occurs;

stopping said motor again;

again reversing the motor direction so that said window shade travelsdownwardly;

setting a counter of said control circuit to a preset numbercorresponding to a home position of said window shade when a change ofstate of said switch again occurs; and

stopping said motor when said shade reaches a preset upper limit.

Other features and advantages of the present invention will becomeapparent from the following description of the invention which refers tothe accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an axial cross-sectional view of a conventional window shaderoller with the shade material not shown.

FIG. 2 is an end view of FIG. 1 as seen from arrows 2--2 in FIG. 1, butalso showing the shade material wrapped on the roller and a typicallocking mechanism.

FIGS. 2A and 2B show a typical prior art inside jamb mounting bracket tomount the barb side of the roller of FIG. 1.

FIG. 3 is an end view of FIG. 1 as seen from arrows 3--3 in FIG. 1.

FIGS. 3A and 3B show a typical inside jamb mounting bracket to mount thepin side of the roller of FIG. 1.

FIGS. 3C, 3D and 3E show a typical universal bracket to mount the rollerof FIG. 1, on the inside or outside of a window frame.

FIG. 4 is a cross-sectional view of FIG. 1 taken across section line4--4 in FIG. 1.

FIG. 5 is a cross-section of the shade of FIG. 1, after its endconnectors have been modified in accordance with the invention to enableit to be used as a part of the motorized system of the invention.

FIG. 6 is a cross-sectional view of FIG. 5, taken across section line6--6 in FIG. 5.

FIG. 7 is an end view of FIGS. 5 and 8 as seen from arrows 7--7 in FIG.5.

FIG. 8 is an axial cross-section of a shade roller made in accordancewith the invention for use as part of the motorized system of theinvention.

FIG. 9 is an end view of FIG. 8 as seen from arrows 9--9 in FIG. 8.

FIG. 10 shows the shade roller of FIGS. 5 or 8 with the shade in place.

FIG. 11 is a side view of FIG. 10.

FIG. 12 is an elevation view of a bracket for the pin or left side ofthe rollers of FIGS. 5 and 8.

FIG. 13 is a side view of the bracket of FIG. 12.

FIG. 13A shows the shade of the invention (FIGS. 5 or 8) installed in awindow opening "inside" the window jambs.

FIG. 14 is an isometric view of the combined mounting bracket and motordrive assembly of the present invention, viewed from below and to theleft of where the assembly would typically be mounted, i.e., the upperright side of a window jamb as viewed from the interior of a room.

FIG. 15 is another isometric view of the assembly of FIG. 14 viewed fromabove and to the left of the assembly mounted in the upper right handcorner of a window opening as viewed from the interior of a room.

FIG. 16 is an exploded perspective view of the assembly of FIG. 14 and15.

FIG. 16A is a rear isometric view of the motor assembly of FIGS. 14-16 ,which illustrates the mounting of Hall effect sensors on the printedcircuit board (PCB) and in quadrature positions adjacent a permanentmagnet on the end of the drove motor shaft, with the mounting bracketnot shown for clarity.

FIGS. 17 to 22 show the operation of the limit paddle of the assembliesof FIGS. 14 to 16 for controlling the limits of shade movement;specifically:

FIG. 17 shows the assembly during winding;

FIG. 17A is a similar view to FIGS. 17 to 22 but shows the shade in its"home" position and showing a preferred "reset" and misaligned/extendinghem bar sensor according to the invention.

FIG. 17B is a view of the rear of the assembly of FIG. 17 with a portionof the PCB broken away to illustrate the limit paddle and itsmicroswitch where the microswitch is in its depressed state.

FIG. 18 shows the assembly when the shade has been wound on the reel toits maximum extent and has pivoted a rise limit lever paddle;

FIG. 18A is like FIG. 17B but shows the limit switch paddle rotated toallow the change of state of the microswitch.

FIG. 19 shows the assembly at the "upper limit" level, which is a userprogrammed level associated with the particular window opening;

FIG. 20 shows the assembly during unwinding when the shade has fullyunwound;

FIG. 21 shows the assembly during unwinding when the shade has fullyunwound and is beginning to wind on the roller in the reverse direction;and

FIG. 22 shows the assembly again during upward winding.

FIG. 23 is a flow chart illustrating the process of setting upper andlower shade limit positions implemented by a program operated by themicro-processor controller of the invention in response to operatorinputs.

FIG. 24 is a flow chart which illustrates the home position resetfunction.

FIG. 25 shows the relationship between upper limit, lower limit, "home"position and fully extended positions.

FIG. 26 is a left end view of FIG. 14.

FIG. 27 is a right end view of FIG. 14.

FIG. 28 is a block diagram of the control system of the motor drive unitof FIGS. 14 to 16.

FIG. 29 is a schematic circuit diagram of an exemplary interconnectionof a plurality of electrical motor drive units according to theinvention.

FIG. 30 is a schematic circuit diagram for the circuit of the blockdiagram of FIG. 28 of the present invention.

FIG. 31 shows two telephone jacks with straight-through pinning.

FIG. 32 is like FIG. 31, but shows crossed pinning.

FIG. 33 shows the position closures of FIGS. 31 or 32 needed to producea shade "raise" operation.

FIG. 34 shows the position closures of FIGS. 31 or 32 needed to producea shade "lower" operation.

FIG. 35 schematically shows the motor drive shaft and sensor magnetaffixed thereto with the direction and speed sensing quadrature sensorsadjacent the sensor magnet during upward shade movement;

FIG. 36 is a timing diagram showing the pulse trains from the sensors ofFIG. 35 during upward movement of the window shade.

FIG. 37 is a table of the sample values for upward and downward shademotion derived from the pulse trains of FIGS. 36 and 39.

FIG. 38 schematically shows the motor shaft and sensors during downwardshade movement.

FIG. 39 is a timing diagram of the pulse trains from the sensors of FIG.38 during downward movement of the window shade.

FIG. 40 shows a flush mount or wall box mountable wall control accordingto the invention.

FIG. 41 shows a surface mount wall control.

FIG. 41A shows an infrared transmitter according to the invention.

FIG. 42 shows how the control circuit responds to control signalsreceived from the controls to operate the shade.

FIG. 43 shows the flow chart for normal operation of the program of thecontrol circuit according to the invention.

FIGS. 44A, 44B and 44C show flow charts which illustrate in more detaila portion of the flow chart of FIG. 43.

FIG. 45 shows the flow chart for the interrupt routine which sets theduty cycle.

FIG. 46 is a perspective view of the motor drive unit showing the"reset" and misaligned/loose hem bar sensor according to the invention.

FIG. 47 shows an alternative embodiment of the invention.

FIG. 48 shows still yet another alternative embodiment of the invention.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring first to FIG. 1, there is shown a sectional view of a priorart manually reelable shade, generally designated 10. The shade 10 has afirst end cap 14 and a second end cap 18 inserted into or otherwisesecured to the opposing ends of a tube 11. The tube 11 is typically madefrom either cardboard, plastic, metal or wood. The shade fabric, (notshown) is attached to the tube 11. The first end cap 14 is permanentlyattached to an end of the tube 11; that is, it is made not to be easilyremoved. Tube 11 and cap 14 together house a spring 20 and a shaft 12.As seen best in FIG. 2, end cap 14 also carries a latch mechanism 13which consists of a conventional pawl latch 13A and projections 13B tohold the roller in a set position. End cap 14 also has a springattachment point 22 to fix the left hand end of spring 20 to the end cap14.

Shaft 12 has a barbed end 26 and an attachment point 24 for the otherend of spring 20. Thus, one end of the spring 20 is connected to thespring attachment end 24 of shaft 12 while the other end of the springis connected to the spring attachment point 22 of end cap 14 and thusthe roller tube 11. The latch mechanism 13 allows the spring 20 to bewound as the tube 11 rotates, and then lock into position when rotationis stopped.

The second end cap 18 houses a supporting pin 16, as best seen in FIG.3. The supporting pin 16 allows the roller to rotate in a suitablebracket. The entire end cap 18 is easily removable to enable adjustmentof the length of the roller 11. Such shades are commercially availableand are stocked by suppliers in standard lengths.

The reelable shade 10 is installed in mounting brackets of the typeshown in FIGS. 2A, 2B, 3A and 3B, or an alternative, as shown in FIGS.3C, 3D and 3E, which are each mounted by screws or nails or the like tothe area, such as the jamb of a window to be covered or uncovered by theshade. If the brackets 28 and 34 of FIGS. 2A, 2B, 3A and 3B are used,the supporting pin 16 is first inserted in the hole 36 of mountingbracket 34. The barb end 26 of the shade is then inserted into itsbracket, e.g., bracket 28 by inserting the barb 26 into the slot 30(FIG. 2B). The shade can then be unwound. While unwinding, the spring 20winds. The latch mechanism 13 allows the shade to be extended to thedesired amount and held in place against the force of the spring 20. Torewind the shade, the latch mechanism is disengaged by pulling the shadedown slightly and then allowing the spring 20 to rotate the roller torewind the shade. In order to prevent the shade from rotating tooquickly, the user holds the shade as the spring rewinds it.

FIGS. 3C, 3D and 3E show a prior art universal mounting bracket 37 thatcan be used at either the left or right hand sides of the shade roller.If used at the left hand side (viewed from the room interior), the barb26 is received in opening 38. The pin 16 end of the roller is receivedin opening 39 of a bracket 37 mounted on the right side. The bracket canbe mounted to the window jambs (inside mounting) via holes 40 or outsidethe window jambs via holes 41.

FIG. 10 shows the conventional reelable shade of FIGS. 1, 2 and 3 withthe shade fabric 40 attached to the tube 11, using staples 46. The shadefabric 40 can be attached to the tube 11 with other kinds of mechanicalfasteners, e.g., tape or glue or the like.

The lower end of shade fabric 40 is folded back upon itself and eitherglued or sewn, forming a loop 43 for receiving a conventional wooden orplastic hem bar 42. See FIG. 11. Hem bar 42 is inserted into the loop 43to add strength and rigidity to the bottom edge of the shade. Suchshades are typically manufactured in 3, 4, 5, and 6 foot widths. If therequired width of the shade for a particular application is differentfrom these widths, the shade width must be modified. This isaccomplished by removing the end cap 18 from the end of the tube 11. Thefabric 40, the tube 11, and the hem bar 42 are then cut to the requiredlength forming a trimmed edge 48. The end cap 18 is then reinstalled inthe end of the tube 11 and the shade assembly 10 can be installed in itsmounting brackets.

In normal operation of the shade of FIG. 1, the user pulls the shadefabric 40 down by grasping the hem bar 42. As the shade fabric 40 isunreeled, the spring 20 is wound. When the appropriate amount of shadefabric is unreeled, the hem bar 42 is gently released and the latchingmechanism 13 locks the shade 10 in position.

FIGS. 5, 6, and 7 show the conventional reelable shade 10 of FIG. 1modified in accordance with the present invention so that it can becontrolled by a motorized arrangement of the invention. Thus, a disk 60with two different sized and orthogonal rectangular cut outs 62 and 63is pressed on to the barb 26. The different sized rectangular cutouts 62and 63 are sized to accommodate different sized conventional barbs witha press fit. The second end cap 18 of FIG. 1 is removed and replacedwith a drive plug 64 as shown in FIGS. 5 and 7. The drive plug 64 has adrive receptacle 66 adapted to receive the output shaft of a drive motoras will be later described. The receptacle can take a variety of shapes,but preferably is a concentric hex drive socket 66. The drive plug 64preferably has suitable serrations around its periphery 64A so as tofrictionally grip the inside of the tube 11.

The hex drive socket 66 is removably installed onto a hex ball outputshaft 102 of a motor control unit 100 according to the invention (FIGS.14, 15, 16, 26, 27) during installation of the reelable shade, while thedisk 60 is inserted into a pivot slot 76 of an idler mounting bracket 70shown in FIGS. 12 and 13. The idler mounting bracket 70 is attached tothe wall or woodwork surrounding the window (or other surface) to becovered or uncovered with screws or nails inserted through the insidejamb mounting holes 74 or outside jamb mounting holes 72. The insidediameter of the pivot slot 76 is sized slightly larger than the outsidediameter of the disk 60 to allow the disk 60 to rotate freely. Thisdisables the latching mechanism 13 and spring 20 of the conventionalreelable shade 10, thus adapting it to motorized use. FIG. 13A shows theretrofitted shade of FIG. 5 installed in a window opening 9 formotorized use in accordance with the invention. As shown there, theshade is installed "inside" the window jamb, but can also be installedoutside the jamb.

FIGS. 8 and 9 show a further embodiment of a reelable shade 78 madeaccording to the invention. The shades of FIGS. 1 to 7 are conventional,retrofitted for motorized use in accordance with the invention, whilethe shade of FIG. 8 is made expressly in accordance with the inventionfor use with and as a part of the motorized system of the invention. InFIG. 8, the shade 78 comprises a shade tube 11 which may be ofconventional design, but has a drive plug 64 (as previously described)and an idler plug 68 at its opposite ends inserted into shade tube 11. Ashade fabric 40 (not shown) is conventionally fixed to the surface ofthe roller 11 of FIG. 8, as in FIG. 10.

With reference again to FIG. 13A, shade 78 is fixed in place byinstalling the drive plug 64 onto hexball 102 of combined bracket andmotor assembly 100, as described. Plug 68 is installed on bracket 70 ofFIGS. 12 and 13 which rotatably receive the plug 68.

FIGS. 14, 15, 16, 16A, 26 and 27 show the combined bracket and motorunit 100, also called herein a motor control unit. FIG. 16 is anexploded perspective view of assembly 100, while FIGS. 14 and 15 showassembly 100 from different angles. FIG. 16A is a rear isometric view ofthe unit 100 with the mounting bracket not shown and FIGS. 26 and 27show left end and right end views of the assembly 100 of FIG. 14.

The motor control unit 100 comprises, as sub assemblies shown in FIG.16, mounting bracket 134, printed circuit board (PCB) assembly 132,motor drive unit 138, housing or enclosure 101 and end cap 124, homeposition and limit paddle 106 and outer brake magnet 142. Also shown isa sensor magnet 136 that mounts on the drive shaft 147 of drive motor146. A cover 127, to be described later, may optionally be provided tocover a portion of housing 101. Also provided are actuator buttons 115for actuating control switches on PCB 133.

The motor control unit 100 can either be mounted to the wall or woodworksurrounding the window or other surface to be covered or uncovered withscrews or other fasteners inserted through outside jamb mounting holes103 or inside jamb mounting holes 104 in the mounting bracket 134.

In order to mount the shade 10, 78, assembly 100 and bracket 70 (FIGS.12, 13 and 13A) are mounted appropriately adjacent the window opening.Viewed from inside the room, unit 100 is mounted in the upper rightwindow corner and bracket 70 is mounted in the upper left window corner.The shade is first placed in position so that plug 64 receives the hexball output shaft 102, to be described in detail later, of motorassembly 100. The left side of the shade 10, 78 is then inserted inbracket 70 so that idler plug 60, 68 is received in slot 76. Thus, shade10, 78 is suspended between bracket 70 (FIG. 12 and 13) and assembly100, as shown in FIG. 13A.

The PCB assembly 132 contains a printed circuit board 133 havingdisposed thereon communication jacks 130, power jack 128, addressswitches 112, home position paddle microswitch 144 as well as a controlcircuit including a microprocessor 152, to be described later. Alsolocated on the PCB 133 are control switches for raising and lowering theshade and a program set actuator. These will be described later.

The power jack 128 receives a low A-C voltage, e.g., 24 volts AC, from aplug-in transformer (not shown) that plugs into a standard 120 VACreceptacle. The plug in transformer is remotely located and is connectedto jack 128 by low voltage wiring.

The communication jacks 130 preferably are standard four-pin modulartelephone jacks, e.g., RJ-11 jacks. These allow multiple motor controlunits 100 to be linked together, using standard four-wire telephonecables with connectors at each end. A circuit will be described belowthat allows use of conventional phone connection wires with eitherstraight-through wiring or crossed wiring, either of which will workproperly among multiple motor control units 100. In accordance with theinvention, the two communication jacks 130 preferably areinterchangeable; there is no dedicated input or output jack, so eitherjack can serve as input or as output.

A decorative cover 127 is optionally provided to cover jacks 130, jack128, associated plug-in wiring therefor and address switches 112. Thecover 127 also serves to keep the plug-in wiring from interfering withthe movement of shade fabric 40.

The home position paddle microswitch 144, which is operated by actuator110 (best seen in FIGS. 17B and 18A) of home position paddle 106, isused to prevent the shade fabric 40 from traveling beyond a shade riselimit when reeling up the shade fabric 40 and also to set a "home"position. In addition, it is used to prevent the shade from travelingpast the fully extended position when unreeling the shade fabric 40. Thehome position switch can also be activated by fabric that bunches up onthe roller. The function of this home position paddle 106 andmicroswitch 144 will be described in detail later.

The motor drive unit 138 of (FIG. 16) houses a drive motor 146 and agear box 148. The motor 146 is preferably a 12-pole, 18 watt DC motorbut can be any type of reversible motor. The gear box 148 is arelatively flat pancake style gear box with a spur gear train (notshown) with the hex ball output shaft 102 extending outward. The gearbox 148 is of the flattened type often used in vending machines andadapts itself to compact mounting in the mounting bracket assembly. In apreferred embodiment, a gear reduction ratio of 119:1 is used. Thedesired output speed of the gear box output shaft is approximately 35rpm, so the drive motor has a nominal rotational speed of approximately4100 rpm.

As previously described, the hex ball output shaft 102 is received inthe hex drive socket 66 of the shade 78 (FIG. 8) or retrofitted shade 10of FIG. 5 during installation. The hex ball and socket constructionpermits a drive connection to the shade 78 even though there may besubstantial misalignment of their respective axes of rotation, due toinstallation misalignment of bracket 70 and unit 100.

When the motor 146 operates, its output shaft 147 is coupled through thegear box 148 to cause the hex ball output shaft 102 to rotate and drivethe hex drive socket 66. This causes the tube 11 to rotate, which inturns reels or unreels shade fabric 40 (FIG. 13A).

A 12-pole DC motor is preferably used to precisely control the rotationand rest position of the shade tube 11. The 12-pole motor has a"cogging" action which can act as a holding brake to prevent the shadefabric from unreeling under its weight after the motor 146 has beenturned off. To stop a shade that is travelling upward or downward,preferably the motor is shorted by the control circuitry.

The driving shaft 147 of the motor 146 extends from both ends of themotor. One end of shaft 147 extends through a hole 135 in printedcircuit board 133, and sensor magnet 136 (FIG. 16A) is press-fit orotherwise secured to the end of the shaft 147 and rotates therewith.Magnet 136 rotates with respect to two quadrature positioned Hall effectsensors 150 (FIG. 16A) which are mounted on the back side of the printedcircuit board 133 and allow the microprocessor to keep track of therotational position, speed and direction of the motor shaft 147, andthus of the hex ball output shaft 102 and shade itself. Details of thisarrangement will be described below.

Preferably extending from the other end of the motor shaft 147 is aninner brake magnet 140. The inner brake magnet 140 rotates inside ofstationary outer brake magnet 142 which provides the motor with agreater holding force when the motor is not energized. The outer brakemagnet 142 is suitably secured in the stationary end cap 124 as withscrews and washers or suitable adhesive to prevent it from rotating.

In some applications, the brake magnets 140 and 142 may be dispensedwith, and all braking action to hold a shade in position will depend onthe cogging action of motor 146.

FIG. 16A shows an isometric rear view of the assembly 100 and inparticular shows the placement of two Hall effect sensors 150 inquadrature (at 90° to one another) which are mounted on the rear side ofthe printed circuit board 133. The motor shaft 147, is shown with thepermanent magnet 136 which rotates with the angular velocity of themotor shaft and is positioned so that sensors 150 are adjacent theperiphery of magnet 136. As a consequence, the output signal of each ofHall effect sensors 150 is a pulse train, in quadrature relationshipwith each other, in which the pulse frequency is a function of motorspeed and the relative pulse spacing between the two pulse trains is afunction of direction of rotation of shaft 147.

FIG. 16A also shows openings such as openings 154A, 154B, 154C and 154Dwhich receive screws, preferably insulating plastic, to fasten the PCB133 to enclosure 101; and bosses such as 155 aligned with mounting holes104 (FIG. 15) which enable mounting of the housing 101 to a mountingsurface. Finally, openings 157 permit mounting of the bracket 134 toenclosure 101.

With reference again to FIG. 16, pivot pin 108 is integral with housing101, and stationary paddle 107 is also molded as part of the housing101. The home position paddle 106 slips over and is rotatably mounted onthe pivot pin 108.

The home position paddle 106 can rotate through a limited arc as shownin FIGS. 17 and 18. The paddle is generally L-shaped, as shown, andcomprises a portion 106A, 106B and a longer extending portion 106C. Inthe rest position of FIG. 17, actuator 110 of the paddle 106 depressesthe operator of microswitch 144 in the embodiment illustrated. This isshown in FIG. 17B in a rear view. When the limit paddle 106 is rotatedclockwise to the position of FIG. 18, the microswitch 144 is in arelaxed or undepressed position. This is shown in FIG. 18A. The limitpaddle 106 will be described in greater detail below.

The housing 101 covers and houses the PCB assembly 132 and the motorunit 138. The tubular extension 126 encloses the DC drive motor 146. Aninfrared port 114 (FIG. 14) allows infrared signals from a hand heldinfrared transmitter to communicate with the motor control unit 100.Alternatively, an RF port or a port responsive to some other frequencyradiation or ultrasonic energy can be used.

Address switches 112 are mounted on the PCB 133 and are exposed throughopening 113 (FIGS. 14 and 17A) in housing 101 to allow the installer toassign the motor control unit 100 a unique address. A unique address maybe required in multiple control unit systems so that the user canindependently control each shade from a control station such as ahand-held infrared transmitter. According to the invention, acommunications port, such as an RS485 serial port, can be provided toenable individual control of a plurality of shades using uniqueaddresses. The invention also encompasses a "contact closure" port, tobe described later, which is not used with addresses, and which onlyenables group control of multiple control unit systems.

With respect to IR port 114 in FIG. 14, it should be noted that aFresnel lens and/or infrared filter (not shown) can be disposed in theopening of port 114 to make collection of infrared signals moreefficient. Furthermore, it is possible to insert an IR conductiveflexible tube or cylinder into opening 114 with its free endconveniently positioned for line of sight reception of infrared signals.For instance, such an infrared conductive tube is disclosed in commonlyowned U.S. patent application Ser. No. 08/713,776 filed Sep. 13, 1996entitled "Infrared Energy Transmissive Member and Radiation Receiver",which is incorporated herein by reference in its entirety. Note thatother radiation signals could be used in place of infrared radiation,including RF signals, sonic signals and light in various bandwidths.

An "up" or "raise" actuator 116 and "down" or "lower" actuator 118 onhousing 101 actuate switches on the PCB board 133 to control rotation ofthe motor 146 so that the shade 78 either reels or unreels its shadefabric. A status LED 120 (FIGS. 14 and 15) flashes at different rates ifdesired, to signal the user that the motor control unit is performingparticular functions. Such functions may include setting the upper andlower limits and setting preset shade positions. Program set actuator122 (FIG. 14) puts the motor control unit 100 into and out of a programmode. The program mode will be described in more detail later. "Raise"actuator 116, "lower" actuator 118 and program set actuator 122 compriseactuator buttons 115 of FIG. 16.

A "home" position is provided. The home position is the relativeposition from which the upper and lower limits are measured and will belater described. The "home" position corresponds to a zero count in aposition memory of microprocessor 152, described in detail below. Thisenables microprocessor 152 to keep track of the shade position.

The installer can manually set the "home" position as shown in FIG. 17A.This is the first action the installer should perform when installing anew shade according to the present invention. The home position is theposition where the hem bar 42 is just touching the limit paddle 106, butthe limit microswitch 144 is not actuated. FIG. 17A shows two hem bars42 and 42A for two alternative shades. The hem bar 42 is the hem bar ofa longer shade than hem bar 42A. For a shorter shade, and consequentlyone that winds into a smaller volume on tube 11, the shade can bedisposed between members 106B and 106C, as shown. In contrast, a longershade, due to its greater winding volume on tube 11, will be threadedbetween members 107 and 106B. If a new shade is installed to replaceanother shade, the user can reestablish the home position. This savesthe installer time because the installer will not have to reset theupper and lower limits which are defined in the microprocessor relativeto the home position.

To set the home position, the installer rotates the limit paddle 106 oractuates actuator 106A manually to actuate microswitch 144 to start thehome position reset function. Alternatively the home position resetfunction could be initiated by a certain sequence of operation of theswitches of a wall control 5001 of FIG. 40 or 6001 of FIG. 41 or bycommands received by the infrared receiver. This operation is shown inFIG. 24 starting at the block 200 "Home position microswitch isactivated while motor is idle". The reset function waits after therelease of the home position microswitch 144 (see FIG. 17B) to allow theuser time to move his hand away from the shade fabric at block 202. Themotor 146 then moves the shade fabric 40 upward until the home positionmicroswitch 144 is activated by hem bar 42 at block 204 (see FIGS. 18and 18A). The motor then waits one half second before reversing themotor direction at block 206. The motor 146 then rotates to move theshade fabric 40 downward until the home position microswitch 144 isreleased at block 208 (see FIG. 17A). In the embodiment illustrated, theactuator of microswitch 144 is depressed, as shown in FIG. 17B. Thiscorresponds to the hem bar just touching paddle 106, as shown in FIG.17A. This is the "home position. The shade position counter of themicroprocessor 152 is reset to zero at block 210 and the motor continuesto unreel shade fabric 40 at block 211 until the upper limit position isreached (see FIG. 19). If the upper limit position is reached at block212, the motor is stopped at block 224 and the routine returns to normaloperation. If the upper limit position is not reached at block 212, themotor control unit continues to unreel the shade fabric. If the "raise"actuator 116 or the "lower" actuator 118 is actuated during this time,the motor 146 is stopped and the motor control unit waits until the"raise" or "lower" actuator is released at block 222. The routine thenreturns to normal operation. If neither the "raise" actuator 116 nor the"lower" actuator 118 are actuated, the routine returns to block 211until the upper limit is reached.

In order to prevent the system from hanging up in the loop 211-214 if noupper limit has been programmed, the system preferably is provided witha default upper limit programmed into memory, e.g. +5 rotations. Inaddition, a default lower limit is also preprogrammed, e.g. +48rotations.

The upper and lower limits (See FIG. 25) are set by the user. The upperlimit is the position where the desired least amount of the shade fabricis showing, as is shown in FIG. 19. This is not to be confused with the"home" position of FIG. 17A, which is typically above the upper limit.The lower limit is the position where the desired most amount of shadefabric is showing. Most often, this is the position where the hem bar 42is slightly above the window sill. This is not to be confused with thefully extended position (FIG. 25), which typically is below the lowerlimit.

When a reelable shade according to the present invention is set up, thesecond action the installer should perform is to establish its upper andlower limits, in accordance with the window opening size.

To set the upper limit, the installer actuates the "up" or "raise"actuator 116 or the "down" or "lower" actuator 118 to move the shadefabric to the desired upper limit position. The installer then actuatesthe program set actuator 122 and then the "up" actuator 116 to store thepresent shade position as an upper limit in a microprocessor memory onPCB 133. To set the lower limit, the installer actuates the "up" or"raise" actuator 116 or the "down" or "lower" actuator 118 to move theshade fabric to the desired lower limit position. The installer thenactuates the program set actuator 122 and then the "down" actuator 118.The upper and lower limits are now stored in microprocessor memorycorresponding to pulse counts of Hall effect sensors 150, to bedescribed in detail below.

The above process is better understood by reference to the flow chart ofFIG. 23. Thus, in FIG. 23, the shade limit position is manually set atblock 180. When the desired position is reached, the program actuatorbutton 122 is actuated momentarily, thus entering the program mode. Ifthe "raise" actuator button 116 is actuated within the next 5 seconds,the upper shade limit position information is stored in themicroprocessor as shown in block 181. For the shade lower limitcalibration, "lower" actuator button 118 is actuated within 5 secondsafter program actuator button 122 to store the lower limit position atblock 182. If neither the raise nor the lower actuator is actuatedwithin 5 seconds the system exits program mode.

Alternatively, the upper and lower limits can be set with commandsreceived through the RS485 serial communication port or through theinfrared receiver.

The paddle 106 may also preferably have a downwardly extending arm 106A,which projects beyond the periphery of the housing 101. The end of sucha downwardly extending arm is shown in FIGS. 17A, 17B and 18A as theportion 106A. The arm 106A serves two functions. A first function is toserve as an extending hem bar 42 (FIG. 11) sensor. The extension 106A islocated in the path of a loose hem bar 42 which may extend beyond theedge of the shade. This prevents the loose extending hem bar fromcontacting the unit 100 as the shade is wound up. However, the extendingloose hem bar 42 will now engage end portion 106A to operate microswitch144 and prevent damage to the shade or unit 100.

The second function is that it allows ease in resetting the unit 100 tothe "home" position.

FIGS. 17, 17A, 18, 19 and 24 show the resetting sequence of events whenthe reelable shade exceeds the home position while the shade istravelling upward. The reelable shade could exceed its home position if,for some reason, the microprocessor gets lost in a routine, if areelable shade is removed and another shade is installed with a lesseramount of shade fabric 40 unreeled, or if the amount of shade fabricunreeled is reduced manually during a power outage and the motor controlunit is subsequently turned on. As the shade fabric 40 is being reeledonto the shade tube 11, the shade fabric 40 passes between thestationary paddle 107 and the limit paddle 106, particularly portion106B, as shown in FIG. 17. The distance between the stationary paddle107 and the limit paddle 106 is enough to let the shade fabric 40 passthrough, but not the hem bar 42. If the reelable shade exceeds the homeposition shown in FIG. 17A, the hem bar 42 forces the limit paddle 106to rotate clockwise as shown in FIG. 18. This changes the state of thelimit microswitch 144 from being depressed as shown in FIGS. 17, 17A and17B to the relaxed position shown in FIGS. 18 and 18A. The changing ofthe state of the limit microswitch 144 is detected by microprocessor 152(FIG. 17B) located on the backside of the PCB 133. The microprocessor152 follows the routine shown in FIG. 24 starting at block 220 "Homeposition micro switch is activated while the motor is moving up". Theroutine continues to block 206, as previously described, reverses themotor direction and moves past the home position (microswitch 144changes state again) and stops at or seeks the upper limit position inaccordance with blocks 210-214 of FIG. 24. See also FIG. 19.

FIGS. 20, 21, 22 and 24 show the resetting sequence of events when thereelable shade 78 unreels the fabric 40 fully and the motor 146continues in the same direction, causing the fabric 40 to begin toreverse roll (FIG. 21). FIG. 20 shows the motor control unit with theshade fabric 40 fully extended. FIG. 21 shows that if the motorcontinues in the same direction, the shade fabric 40 will reverse inrotation on the roller and engage with the limit paddle 106, inparticular with the extending portion 106C, to cause the limit paddle106 to rotate clockwise, changing the state of the limit microswitch144. The changing of the state of the limit microswitch 144 is detectedby the microprocessor 152. The microprocessor 152 then follows theroutine shown in FIG. 24 starting at block 216 "Home position microswitch is activated while the motor is moving down". Thus, themicroprocessor 152 will determine that a reversal of wrap direction hasoccurred and will initiate corrective action. According to FIG. 24, themotor 146 is then stopped and the routine waits one half second beforereversing the motor direction (218), as shown in FIG. 24. Themicroswitch then returns to the depressed (normal) state again. Theroutine then continues to block 204, the shade moves upwardly until thehome position microswitch changes state when hem bar 42 hits the limitpaddle 106, reverses direction again, goes past the home position andseeks the upper limit, as shown at step 204-212. It then follows theflow chart as described before, as shown in steps 204-214. Accordingly,if a wrap reversal occurs as shown in FIG. 21, the end result will bethat the system returns the shade to the upper limit. Alternatively, thesystem could be programmed, if desired, to return the shade to the lowerlimit if a wrap reversal occurs.

FIG. 28 is a block diagram of the circuit of the motor control unit 100.

The circuit of control unit 100 comprises a power supply 300 whichsupplies two voltages, 30 volts for motor drive 302 and 5 volts forlogic control supplied to all of the other circuits which comprise themotor control unit 100. The 30 volt output from the power supply 300 isprovided to the motor drive circuit 302 which preferably comprises anH-bridge circuit. An output is provided from the motor drive 302 to themotor 146. The output is indicated at 320.

The main logic unit of the control circuit comprises a logic unit 308comprising a microprocessor 152. The logic control unit 308 has aplurality of inputs and a plurality of outputs. The inputs include aninput from a motor speed and direction sensing circuit 304 which isprovided with inputs from the Hall effect sensors 150 mounted on theprinted circuit board 133. Also provided to the logic unit 308 areinputs from the various actuators 116, 118 and 122 which are indicatedin the block diagram at 310. These buttons include the "raise", "lower"and "program set" buttons previously described. An additional input tothe logic unit 308 comprises the home position switch 144, indicated asblock 312 in FIG. 28.

Also provided to the logic unit 308 is an input from an IR/RF receiver314. By way of the receiver 314, a user may control the operation of awindow shade or plurality of window shades, each of which is controlledby a unit 100 from a remote location.

Logic unit 308 also communicates with a non-volatile storage 316,preferably an EEPROM, in which program control is stored. The logic unit308 also communicates with a communications port 318, the purpose ofwhich is to allow a plurality of motor control units 100 to beinterconnected and communicate with each other and with control devices,such as wall mounted controls. Via the communications module 318, eachmotor control unit can communicate with other motor control units,sending information for the control of other units and receive necessaryinformation from the other units for its control. The communicationsport 318 has a portion 318A that preferably communicates with othercontrol modules via telephone type connectors, and is polarityinsensitive, as will be described below in further detail.

The communications port 318A preferably is a contact closure transceiverwhich communicates contact closure information to the microprocessor tocontrol raise and lower and preset functions. Also, the portion 318Aallows contact closure information to be transmitted to other units 100that are connected to the controlled unit 100. For example, a particularunit 100 may receive control information from an infrared transmittervia receiver 314. This control information must also be passed to otherunits 100 not within range of the infrared transmitter that are to becontrolled simultaneously with the motor control unit 100 and that arewired to the motor control unit 100 that receives the infrared signalvia its receiver 314.

In the preferred embodiment, when IR receiver 314 receives controlinformation, it is provided to microprocessor 152 of logic unit 308.Microprocessor 152 issues command signals to communications circuit 318Awhich are transmitted to other modules 100 operating other shades.Additionally, microprocessor 152 of the motor control unit 100 thendetects the command signals at the communications jacks 130 of circuit318A to command the original unit 100 also to the desired shadeposition. So, according to the illustrated embodiment, before the unit100 actually responds to the IR receiver, it sends the controlinformation to the communication circuit 318A. The microprocessor thenreceives this same control information from communication circuit 318Ato effect the desired shade repositioning. This is done in this manneronly because it is necessary to put the control information on thecommunication link for receipt by all connected modules 100.

Communication port 318 also includes a portion 318B that may comprise aserial port for the communication of control information among remotecomputers, controllers, timers, etc. and the units 100. It may comprise,e.g., a type RS485 port. Use of a serial port such as an R5485 port alsoenables the communication of commands other than "raise", "lower", "homeposition reset", etc., such as "All the way up" or "All the way down" or"Go to a preset shade position".

Address switches are necessary in order to control shades independently.Individual motor control units can be selected for control from aninfrared or radio frequency transmitter with an address selector switchon the transmitter. Individual shades or groups of shades can becontrolled from a wall control or infrared or radio frequencytransmitter. The motor control units can be linked together throughwiring (not shown). The units may communicate using an RS485 protocol.The RS485 link allows the motor control unit or units to be interfacedwith motion sensors, occupancy sensors, time clocks and similar devices.The RS485 link also allows multiple preset shade positions to be storedinto memory for recall later.

The logic unit 308 controls the motor drive 302 via a pulse widthmodulator 306. The pulse width modulator 306 modulates the duty cycle ofpulses supplied to the motor drive 302 to control the speed anddirection of the drive motor. Preferably, as will be described below,the pulse width modulator 306 seeks to maintain a constant rotationalspeed of roller 11 of about 35 rpm. Other rotational speeds can be usedas required.

FIG. 30 is a schematic circuit diagram of each of the blocks describedwith reference to FIG. 28, but does not show details of block 318B whichare conventional. The power supply is indicated at 300 and includes abridge rectifier 3001 for providing a 30 volt DC power level 3002 forthe motor drive 302. The 30 volt level is supplied to a regulator 3004for providing a 5 volt logic level 3003.

The logic unit 308 comprises microprocessor 152, for example, a MotorolaHC6805P4 microprocessor. The microprocessor is coupled to a non-volatilememory 316 comprising an EEPROM. A reset circuit 3081 of known design iscoupled to the microprocessor 152. A clock circuit 3082 operating at afrequency of 4 MHz is provided for controlling the program cycle time.

A plurality of switches labeled UP 3116, DN 3118 and SET 3122 comprisethe button inputs 310. These switches serve, respectively, as the"raise", "lower" and "program set" switches, previously described. Theswitches are coupled to pull-up resistors and the connections of thepull-up resistors and the switches are provided to appropriate inputports of the microprocessor 152 for control purposes.

The "raise" and "lower" switches on the motor control unit 100 indicatedat 310 in FIG. 30 can allow the shade to exceed the upper and lowerlimits, as previously described. In contrast, like switches contained onremote and/or wall mounted controls (see FIGS. 40, 41, and 41A) onlyallow movement between the upper and lower limits.

The infrared receiver 314 is provided as shown and coupled to an inputof the microprocessor 152 for providing remote control of the windowshade. The home position switch 144 is indicated at 312 and is coupledto a pull-up resistor with the connection between the switch and thepull-up resistor being provided to an appropriate input terminal of themicroprocessor 152. Hall effect sensors 150 comprising a part of motorspeed and direction sensing circuit 304 are coupled to terminals of themicroprocessor 152 for determining the position of the shade and formonitoring the speed and direction of the shade.

The motor drive circuit 302 is controlled by a pulse width modulatorcircuit 306. In the preferred embodiment, the pulse width modulatorcircuit 306 receives an approximately 2 KHz duty cycle modulated signalfrom the microprocessor 152. The PWM circuit 306 reads the duty cyclemodulated signal as an average DC level and uses it to set the pulsewidth for a pulse width modulated 20 KHZ signal which is provided to themotor drive circuit 302. The PWM circuit outputs this signal on line3061. The motor drive 302 receives the signal on lines 3023 and 3024through diodes D7 and D6. The PWM circuit 306 outputs the signal at 20KHz so that audible noise is not generated. The outputs of themicroprocessor 152 are provided directly to the motor drive circuit 302on lines 3021 and 3022. The microprocessor 152 signals the motor drive302 to brake, rotate the motor in a forward direction or rotate themotor in a reverse direction on lines 3021 and 3022. The pulse widthmodulator output 3061 is coupled to diodes D6 and D7 via lines 3023 and3024. The output 3061 of the pulse width modulator modulates the signalson lines 3021 and 3022 from the microprocessor 152 by the operation ofdiodes D6 and D7. The pulse width modulated signal is applied totransistors Q10 and Q11 and Q3 and Q4. The motor 146 is connected topower transistors Q5, Q6, Q7 and Q8, e.g. power MOSFETS, connected in anH-bridge arrangement.

FIG. 35 shows the output shaft 147 of the drive motor 146 and sensormagnet 136 fastened to the shaft 147. Also shown are the Hall effectsensors 150 identified as sensor 1 (S1) and sensor 2 (S2). These sensorsare in quadrature relationship, meaning they are 90° apart. If thewindow shade is moving in an up direction, corresponding to the motordirection indicated by the arrow in FIG. 35, the pulse trains fromsensors 1 and 2 are in the relative position shown in FIG. 36, that is,they are 90° out of phase with sensor 1 leading sensor 2. As will bediscussed hereinbelow, the microprocessor detects the speed based uponthe change in number of revolutions over time, the microprocessor countsthe number of revolutions in a 1/2 second period. The microprocessorsamples the output from each of the sensors, for example, four samples,as shown in FIG. 36. The microprocessor samples both the outputs fromsensor 1 and sensor 2 and compiles a table of the samples, as shown inFIG. 37 for the up pulse trains.

At 35 RPM with a gear ratio of 119:1, the time for a 1/2 cycle of thepulse train is approximately 0.007 sec. The microprocessor 152 samplesthe hall effect sensors 150 every 572 μ second. Therefore, themicroprocessor will receive approximately 12 samples per 1/2 cycle. Themicroprocessor samples every 572 μ sec. regardless of motor speed.

FIG. 38 shows the motor shaft 147, magnet 146 and Hall effect sensors150 while the shade is being moved down. FIG. 39 shows the relationshipbetween the sensor 1 and sensor 2 signals while the shade is movingdown. Again, the signals are in quadrature relationship. However, thesensor 1 signal now trails the sensor 2 signal by 90°. Again, in theexample shown, four samples are taken of the sensor 1 and sensor 2signals. The samples for the down pulse trains of FIG. 39 are alsocompiled as shown in FIG. 37.

As shown in FIG. 37, for the up pulse trains of FIG. 36, for sample 1,the outputs of sensor 1 and sensor 2 are 0. For sample 2, the outputs ofsensor 1 and sensor 2 remain 0. For sample 3, the output of sensor 1 isnow 1 and the output of sensor 2 is 0. For sample 4, the output ofsensor 1 is 1 and the output of sensor 2 is 0. Similarly, for the downpulse trains of FIG. 39, the sensor 1 and sensor 2 outputs for the foursamples are as shown. The microprocessor can determine the direction ofrotation based upon finding the changes in the up and down sequencesindicated in FIG. 37.

The microprocessor 152 keeps track of the position of the shade. Thiscan be performed by incrementing/decrementing a 16 bit position memoryby subtracting one from the total for each "up" revolution of a motorand by adding one to the memory total for each revolution of a motorthat is proceeding down. Position is determined from the "home" positionwhich is 0. The direction is determined by looking for the changes inthe sequences of FIG. 37. Thus, when the motor travels one revolutiondownwardly from the home position, the position memory it will have atotal of +1. When the motor has traveled, for example, 48 revolutions,the memory count will be +48. When the shade then proceeds upwardly itwill be decremented for each motor revolution until reaching the homeposition again.

The aim of the pulse width modulator 306 is to control the motor speedso that it is nearly constant. If the speed is not within the desiredrange, which is illustratively 34 to 36 rpm of the shade reel, the dutycycle is changed according to the attached table, to give the desiredchanges in duty cycle, Δdc, applied to the motor.

                  TABLE I                                                         ______________________________________                                        Relative                                                                      Speed  RPM      Δdc = change in duty cycle to PWM 306                   ______________________________________                                                        circuit                                                       Very   43       -8 = decrease by 16 μ sec                                  High   42                                                                            41                                                                     Hi     40       -1 = decrease by 2 μ sec                                          39                                                                            38                                                                            37                                                                     Ok     36       0                                                                    35                                                                            34                                                                     Low    33       +1 = increase by 2 μ sec                                          32                                                                            31                                                                            30                                                                     Very   29       +8 = increase by 16 μ sec                                  Low    28                                                                            27                                                                     ______________________________________                                         A "unit" change in the duty cycle corresponds to a 2 μ second change. 

In the preferred embodiment of the invention, the period of the pulsewidth modulated reference signal is 572 microseconds corresponding to afrequency of 1.748 kHz. The duty cycle can be changed between a minimumpulse width of 64 microseconds and a maximum pulse width of 416microseconds.

Further details concerning the pulse width modulator circuit 306 will bedescribed later.

Details of the communication circuit 318 will now be described.

The system of the invention preferably uses simple contact closures tocommunicate "raise", "lower", and "toggle" commands to motor controlunits 100 that are connected together or to communicate between acontrol unit 100 receiving a command and other connected control units.Preferably, the wiring connections are made using standard telephonecables because they are readily available and make installation easy.For example, standard RJ-11 jacks and wiring connected to such jacks maybe used.

A typical installation is shown in FIG. 29. As shown in FIG. 29, a wallcontrol unit 5001 (also see FIGS. 40 and 41) which has "raise" and"lower" buttons is plugged into a communications port 130 of a motorcontrol unit 100 via a telephone type cable 5004. The wall control,indicated at 5001, thereby can communicate and control the plurality ofmotor control units 100. A splitter 1002 for interconnecting telephonecables such as RJ-11 type connections, may be provided to couple anumber of units from the same telephone connector. In this manner, asingle wall control 5001 can control a number of motor control units100.

Also shown in FIG. 29 is an IR transmitter 7001, whose output can bereceived by the IR port 114 of at least one of the modules 100 forcontrolling one or more the connected modules 100.

A problem is that it cannot be insured that motor control units 100 andwall controls 5001 will be wired in parallel, i.e., so that conductorsof a telephone cable correspond between each unit. This is becausestandard telephone cables typically comprise 4 lines and usually reversethe pin-out so that pin 1 becomes pin 4 on the other end of the cable.Pin 2 becomes pin 3. This is so-called cross-pinning and is shown inFIG. 32. There are also telephone cables that have "straight-throughpinning" that are used for data communications. This is shown in FIG.31. Installers of telephone cables may or may not reverse the pin-out.Additionally, the use of splitters 1002 complicates matters even moresince using two telephone cables could introduce two reversals.Accordingly, to make installation simple, and in order to use themodular RJ-11 type connections, it is preferable that a flexiblearrangement that can tolerate either configuration be used.

According to the invention, a communication circuit 318A is providedthat can handle both cross-pinned and straight-through pinned cables.Further, there are no dedicated input and output jacks on the motorcontrol units 100, according to the invention. The installer can plugthe modular telephone cable into either one of the two jacks 130. Inthis way, both jacks serve as either inputs or outputs. Also, theinstaller will not have to worry about what type of cable he has, i.e.,whether cross-pinned or straight-through pinned. Circuit 318A insuresthat there are no restrictions on how the motor control units 100 andwall controls are wired together. Additionally, splitter 1002, as shownin FIG. 29, can be used as needed without having to be concerned aboutwhether crossed or straight-through pinning is used.

The theory of operation of the communications circuit 318A is asfollows. "Raise" and "lower" signals are defined as follows: A "raise"signal is a closure between one of the two inner conductors, either 2 or3 and the adjacent outer conductor, 1 or 4 respectively. This is shownin FIG. 33. Similarly, a "lower" signal is defined as a closure betweenan inner conductor and the outer conductor which is not adjacent.

Accordingly, closures between 1 and 2 or 3 and 4 are "raise" signals, asshown in FIG. 33. Closures between 1 and 3 or 2 and 4, which are notadjacent, are "lower" signals. FIG. 34 shows examples of "lower"signals.

Circuit 318A thus operates as follows: With reference to FIG. 30,transistor Q61 has its collector coupled to an input of themicroprocessor 152. Its base is coupled to pin 4 of the twocommunication ports 130 which are wired in parallel. Transistor Q62 hasits collector coupled to an input port of microprocessor 152 and has itsbase coupled to pin 1 of ports 130 and to the emitters of transistorsQ64 and Q66. Transistor Q64 is the "lower output transistor". TransistorQ66 is the "raise output transistor". Transistor Q63 has its basecoupled to lines 2 of the communications ports 130 and transistor Q65has its base coupled to lines 3 of the communication ports 130. Thecollector of transistor Q63 is coupled to an input port of themicroprocessor 152 and the collector of transistor Q65 is coupled toanother input port of the microprocessor 152. The base of transistor Q63is connected to the collector of transistor Q66 and the base oftransistor Q65 is connected to the collector of transistor Q64. Therespective bases of transistors Q66 and Q64 are coupled to respectiveoutput ports of the microprocessor 152. As shown, in the embodimentillustrated transistor Q61, Q62, Q64 and Q66 are NPN transistors andtransistors Q63 and Q65 are PNP transistors.

The circuit operates as follows. If a raise signal is received, i.e., aclosure between pins 1 and 2, the bases of transistors Q62 and Q63 arecoupled together at jacks 130. The collector of transistor Q63 goes highand the collector of transistor Q62 goes low, informing microprocessor152 that a closure has occurred on lines 1 and 2 and that the raisesignal should be issued to the motor drive circuit. If the raise signalis instead received due to closure of contacts 3 and 4, transistor Q65is turned on and transistor Q61 is also turned on, providing high levelsto respective input ports of the microprocessor 152. Accordingly, a"raise" signal is issued to the motor drive circuit.

In contrast, if contacts 1 and 3 are closed, i.e., a "lower" signal isreceived, the transistor Q62 is turned on and transistor Q65 is turnedon, thereby providing an indication to the microprocessor 152 that a"lower" signal has been received. Similarly, if contacts 2 and 4 areclosed, transistor Q63 is turned on and transistor Q61 is turned on,also providing appropriate inputs to the microprocessor 152 so that a"lower" signal can be issued to the motor drive circuit.

If the microprocessor 152 receives a "raise", "lower" or "toggle" signalfrom another control device, for example, the infrared transmitter,those signals will be received from IR circuit 314 by themicroprocessor. The microprocessor will then issue outputs to theappropriate transistor Q66 or Q64, or both. In the case of a "raise"output signal, transistor Q66 will be turned on, thereby shorting pins 1and 2 to provide the "raise" output signal on the port 130. Similarly,If a "lower" output signal is issued by the microprocessor, transistorQ64 will be turned on, thereby shorting pins 1 and 3, providing a"lower" signal on the ports 130. Because other units 100 have the samecircuit 318A, they will detect the closure of lines 1 and 2 as a "raise"signal, despite straight-through or crossed pinning and the closure oflines 1 and 3 as a "lower signal", despite straight-through or crossedpinning. Also, as described above, the unit 100 issuing the "raise" or"lower" command responds to the command based upon detection thereof bythe communication circuit 318A.

The following table of possible contact closures verses signals to themicroprocessor is implemented by the circuit 318A of FIG. 30.

                  TABLE 2                                                         ______________________________________                                        Tables of Possible Contact Closures                                           vs. Signals to the Microcontroller                                            ______________________________________                                        "Pin 1 transistor" refers to Q62 in the circuit diagram of FIG. 30.           Pin 1 transistor is normally OFF                                              "Pin 2 transistor" refers to Q63 in the circuit diagram of FIG. 30.           Pin 2 transistor is normally OFF                                              "Pin 3 transistor" refers to Q65 in the circuit diagram of FIG. 30.           Pin 3 transistor is normally OFF                                              "Pin 4 transistor" refers to Q61 in the circuit diagram of FIG. 30.           Pin 4 transistor is normally OFF                                              "Raise output transistor" refers to Q66 in the circuit diagram of             FIG. 30.                                                                      "Lower output transistor" refers to Q64 in the circuit diagram of             FIG. 30.                                                                      ______________________________________                                         *An asterisk means that the state of the transistor has switched from its     normal state.                                                            

                  TABLE 2A                                                        ______________________________________                                        Raise output transistor is OFF                                                Lower output transistor is OFF                                                                        External closures                                             None  1 & 2  1 & 3  2 & 4                                                                              3 & 4                                                                              1 & 4                                                                              2 & 3                              ______________________________________                                        Pin 1 transistor  *      *                                                    Pin 2 transistor  *           *                                               Pin 3 transistor         *         *                                          Pin 4 transistor              *    *                                          Interpretation    raise  lower                                                                              lower                                                                              raise                                      ______________________________________                                    

                  TABLE 2B                                                        ______________________________________                                        Raise output transistor is ON                                                 Lower output transistor is OFF                                                                        External closures                                             None  1 & 2  1 & 3  2 & 4                                                                              3 & 4                                                                              1 & 4                                                                              2 & 3                              ______________________________________                                        Pin 1 transistor  *      *              *                                     Pin 2 transistor  *           *              *                                Pin 3 transistor                                                                        *       *      *    *    *    *    *                                Pin 4 transistor                                                                        *       *      *    *    *    *    *                                Interpretation                                                                          raise   both   both both raise                                                                              both both                             ______________________________________                                    

                  TABLE 2C                                                        ______________________________________                                        Raise output transistor is OFF                                                Lower output transistor is ON                                                                         External closures                                             None  1 & 2  1 & 3  2 & 4                                                                              3 & 4                                                                              1 & 4                                                                              2 & 3                              ______________________________________                                        Pin 1 transistor  *      *              *                                     Pin 2 transistor                                                                        *       *      *    *    *    *    *                                Pin 3 transistor         *         *         *                                Pin 4 transistor                                                                        *       *      *    *    *    *    *                                Interpretation                                                                          lower   both   both lower                                                                              both both both                             ______________________________________                                    

                  TABLE 2D                                                        ______________________________________                                        Raise output transistor is ON                                                 Lower output transistor is ON                                                                         External closures                                             None  1 & 2  1 & 3  2 & 4                                                                              3 & 4                                                                              1 & 4                                                                              2 & 3                              ______________________________________                                        Pin 1 transistor  *      *              *                                     Pin 2 transistor                                                                        *       *      *    *    *    *    *                                Pin 3 transistor                                                                        *       *      *    *    *    *    *                                Pin 4 transistor                                                                        *       *      *    *    *    *    *                                Interpretation                                                                          both    both   both both both both both                             ______________________________________                                    

In the above Table 2, "both" means that both the "raise" and "lower"buttons have been actuated at the same time on a control device, e.g.,the flush wall mount control of FIG. 40, or that the toggle switch 7003of the remote transmitter shown in FIG. 41A or the toggle switch 6003 ofthe surface wall mountable control of FIG. 41 has been activated. Thereaction of the window shade is shown in FIG. 42, based on the controlinputs and the present state of the shade. In a preferred embodiment ofthe invention, the flush wall mount control 5001 has raise button 5000and lower button 5002 which operate raise and lower switches (notshown). It communicates with modules 100 via the telephone style cable5004 having modular telephone plugs 5006 and 5008 at each end. Plug 5006plugs into a modular jack on control 5001 and plug 5008 plugs into ajack 130 on a motor unit 100. See FIG. 40.

In contrast, in a preferred embodiment of a surface mount control 6001,shown in FIG. 41, a toggle button 6003 is provided which operates in thesame way as when both buttons on control 5001 are depressed, i.e., asshown in FIG. 42. This control also has raise and lower buttons 6000 and6002. Buttons 6000, 6002 and 6003 operate switches (not shown). Theinfrared control 7001 (FIG. 41A) also has a toggle button 7003 and raiseand lower buttons 7000 and 7002 which operate respective switches (notshown) which operate to produce the desired commands.

FIGS. 43, 44A, 44B, 44C and 45 are flow charts for normal operation ofthe motor control unit and a flow chart for the interrupt routine whichsets the duty cycle, respectively. These flow charts are implemented bymicroprocessor 152. With reference now to FIG. 43, this figure shows theflow chart for normal operation of the motor control unit 100.

Normal program operation starts at step 2002. Next the status of thehome position switch and the raise, lower and program set actuators ischecked at 2004 and a corresponding motor command is generated. If thehome position switch has been activated (i.e. released) a Home PositionSwitch Activation Command is generated. If the raise actuator has beenoperated a "Raise without Limits" command is generated. If the loweractuator has been actuated a "Lower without Limits" command isgenerated. If the program set actuator is actuated for less than onesecond and then the raise actuator is operated within 5 seconds, a "setUpper Limit" command is generated. If the program set actuator isactuated for less than one second and then the lower actuator isoperated within 5 seconds a "Set Lower Limit" command is generated. At2006 the status of contact closures at the communications ports 130 arechecked via circuit 318A to receive commands from wall controls andother control units or other devices such as occupancy sensors etc. Acorresponding motor command signal is generated in response. If contacts1 and 2 or 3 and 4 are changed from their normal states, i.e., they areshorted together, then a "raise" command is generated. If contacts 1 and3 or 2 and 4 are changed from their normal states, i.e., they areshorted together, then a "lower" command is generated. If contacts 1,2and 3 or contacts 2, 3 and 4 are changed from their normal states, i.e.,they are shorted together, then a "Toggle" command is generated.

Also at step 2006 any contact closure commands previously generated inresponse to a received Infrared signal are implemented. If the contactclosure command is "Raise" then contacts 1 and 2 are activated. If thecontact closure command is "Lower" then contact 1 and 3 are activated.If the contact closure command is "Toggle" then contacts 1, 2 and 3 areactivated.

Further at step 2006 optional RS 485 communications circuit 318B can bechecked for any received command. At step 2008, the infrared input fromreceiver 314 is checked and a contact closure command is generated asappropriate. The possible received infrared commands are "Raise,"Lower", and "Toggle", which generate corresponding contact closurecommands. These contact closure commands are implemented by themicroprocessor 152 at step 2006 the next time through the program cycle.At 2010, a determination is made if a new motor command has beenreceived.

If a new motor command has been received then it is processed asillustrated in more detail in FIGS. 44A, 44B and 44C. The program entersblock 2010A from block 2008 and then proceeds to block 2010B where newlyreceived commands are processed. If a "Home Position Switch Activation"command has been received or a "Home Position Reset Function" commandhas been received (This could have been received through the optionalRS485 circuit 318B or, alternatively, the microprocessor 152 couldautomatically generate a "Home Position Reset Function" command afterthe shade has been moved to the Upper Limit a certain number of times.This enables the system to automatically recalibrate itself and ensurethat the shade position at the upper and the lower limits is accurate.)then the Home position reset function is executed as shown in moredetail in FIG. 24.

If a "Stop" command has been received (through the optional RS485circuit or otherwise) then the motor is braked and the duty cycle of PWMcircuit 306 is set to zero. If a "Set Upper Limit" command has beenreceived then the current shade position is stored as the Upper Limit.If a "Set Lower Limit" command has been received then the current shadeposition is stored as the lower limit.

If a "Raise" command has been received then the shade is raised whilethe command is being sent. If the "Raise" commands is a "Raise WithoutLimits" command, then the shade can be raised past any previously setupper limit. Similarly if a "Lower" command has been received then theshade is lowered while the command is being sent. If the "Lower" commandis a "Lower Without Limits" command then the shade can be lowered pastany previously set lower limit.

If an "All the Way Up" command or an "All the Way down" command isreceived, then the shade is raised all the way up until the upper limitis reached or lowered all the way until the lower limit is reachedrespectively. These commands could be received through the optionalRS485 circuit or otherwise.

If a "Toggle" command has been received this is interpreted in one ofthree ways. If the shade has been idle for 5 seconds the shade is raiseduntil the upper limit is reached. If the shade is currently moving thenthe shade is stopped. If the shade is currently idle but for less then 5seconds then the shade is raised to the upper limit or lowered to thelower limit whichever is the opposite of the last movement of the shade.

The program then proceeds to block 2010C where the specific commandsbeing sent to the motor through PWM circuit 306 and motor drive circuit302 are updated.

The first thing that is done is a limit check. If the shade is movingup, and the position counter indicates that the upper limit has beenreached, the motor is stopped. Similarly if the shade is moving down andthe position counter indicates that the lower limit has been reached themotor is stopped. However, if the motor is moving in response to a"Raise Without Limits" or a "Lower Without Limits" command then themotor would continue moving the shade past the upper or the lower limit.

Next the direction set outputs 3021 and 3022 are adjusted. If thecurrent motor command indicates that the motor is to be moved in a raisedirection, then output 3021 will be high and output 3022 will be low. Ifthe current motor command indicates that the motor is to be moved in alower direction, then output 3021 will be low and output 3022 will behigh. If the motor is to be stopped or braked both outputs 3021 and 3022will be high or both outputs 3021 and 3022 will be low.

Finally, the speed of the motor is updated. The current speed of themotor is determined by comparing the current position of the shade withthe previous position of the shade. These positions are read from theregisters where they were stored after reading the Hall Effect sensors.

As described in more detail with reference to Table 1 above, if thespeed of the shade reel is less than 29 RPM then the duty cycle isincremented by 8, if the speed of the shade reel is between 30 and 33RPM the duty cycle is incremented by 1. If the speed of the shade reelis between 34 and 36 RPM no change is made to the duty cycle. If thespeed of the shade reel is between 37 and 40 RPM then the duty cycle isdecremented by 1 and finally if the speed of the shade reel is greaterthan 41 RPM the duty cycle is decremented by 8. Each unit increment ordecrement of the duty cycle is equal to a change of 2 μ seconds.

The program exists block 2010C and returns to block 2014 at FIG. 43. At2014, the changed motor direction and duty cycle signals are written tothe EEPROM non-volatile storage. A return is then made to the start ofthe main loop 2002 at which the cycle repeats.

FIG. 45 shows the flow chart for the duty cycle interrupt routine whichsets the duty cycle. The interrupt routine begins at step 4000 as aresult of the PWM output changing state from high to low or low to highand proceeds to step 4002. At step 4002 the time and output level of thenext interrupt is set. If the interrupt routine is entered as a resultof the output from the PWM circuit going low then a determination ismade as to whether the duty cycle is set to zero. If it is, the outputis set to go low again in 572 μ seconds. If the duty cycle is not equalto zero, the output is set to go high at a time in the future determinedby the desired duty cycle as determined at block 2010C of the mainprogram flow.

If the interrupt routine is entered as a result of the output from thePWM circuit going high then the output is set to go low at a time in thefuture determined by the desired duty cycle as determined at block 2010Cof the main program flow. Hence the interrupt routine will be enteredonce every 572 μ seconds if the duty cycle is zero and twice every 572 μseconds if the duty cycle is not equal to zero (once when the PWM outputgoes from low to high and once when the PWM output goes from high tolow).

At block 4004 a determination is made as to whether to sample the IRreceiver and Hall Effect sensors. If less than 572 μ seconds haveelapsed since the last samples were taken then the interrupt routine isended and control of the microprocessor 152 returns to the main programillustrated in FIG. 43.

If 572 μ seconds have elapsed, the IR receiver is sampled at block 4006and any received signals are stored for later interpretation at block2008 of the main program. The interrupt routine then continues at block4008 where the Hall Effect sensors are sampled as described in moredetail above with reference to FIGS. 35, 36, 37, 38 and 39 and thecurrent position of the shade is stored in memory for later use by block2010C of the main program.

The interrupt routine is ended and control of the microprocessor returnsto the main program illustrated in FIG. 43.

FIG. 47 shows a further embodiment of the invention. In this embodiment,motor drive unit 100 has coupled thereto a free hanging Raise/Lowerswitch wand 600 which comprises a rod or conduit for control wires. Thecontrol wires are preferably coupled electrically to the communicationports 130. In particular, they may plug into a port 130 or be wired inparallel to the communication port connectors. The Raise/Lower/toggleswitches are disposed at the lower end 602 of the rod or conduit 600 andcontrol the motor drive unit 100 in the same way as the remote controls,e.g. 5001, 6001, 7001, to raise and lower the shade. The wires in therod conduit 600 can couple to the communication jacks 130 using amodular telephone plug. The rod/conduit 600 may be coupled to the unit100 using a hook which can be disposed in different locations toaccommodate the particular installation.

FIG. 48 shows another embodiment having a wand 700 that is turned clockwise/counter clockwise to, e.g., lower or raise, respectively, theshade. The wand 700 is similar to the wand employed on conventionalslatted window blinds. It can be attached to the unit 100 via a hookwhich operates a raise/lower switch provided on unit 100. Alternatively,it can be coupled to unit 100 in some other way to actuate a raise/lowerswitch. A twist to the right (counter clockwise) actuates a switch inthe unit 100 that raises the shade and a twist to the left (clock wise)actuates a switch in the unit 100 that lowers the shade. The switchesmay be coupled in parallel to the communication jacks 130.

In the embodiments of FIGS. 47 and 48, the switches at 602 or operatedby wand 700 can be in addition to switches 116 and 118 or can beprovided instead of switches 116 and 118.

Although the present invention has been described in relation toparticular embodiments thereof, many other variations and modificationsand other uses will become apparent to those skilled in the art.Therefore, the present invention be limited not by the specificdisclosure herein, but only by the appended claims.

What is claimed is:
 1. A unitary bracket and motor drive for an elongated reelable shade; said motor drive comprising a reversible DC motor coupleable to a source of DC power, a control circuit for coupling said source of DC power and said motor, a microprocessor for controlling the sequence and operation of said motor, a motor operation sensor coupled to said microprocessor, and an input control signal sensor connected to said microprocessor; a gear reduction train assembly having an input shaft end connected to the output shaft of said motor and an output shaft end connected to an output drive shaft which is connectable to one end of said shade; a unitary housing for enclosing said motor, control circuit, microprocessor, motor operation sensor, and gear reduction train; said bracket being fastened to said unitary housing; a shade end position switch within said housing coupled to said microprocessor; and a pivotally mounted sensor coupled to said end position switch for sensing end positions of said shade.
 2. The unitary bracket and motor drive of claim 1, in which said pivotally mounted sensor has a shade home position lever arm and a shade fully extended lever arm; said shade home position lever arm extending substantially perpendicularly to the path of movement of said shade; said shade home position lever arm being rotated when a hem bar of said shade passes and engages said shade home position lever arm; said shade fully extended lever arm having a free end disposed adjacent to but spaced from a surface of said shade mounted by said bracket, and being rotated in response to the wrapping of said shade in an opposite direction on its reel after said shade has been unwrapped to its full extent.
 3. An apparatus for controlling operation of a motorized window shade, said apparatus comprising a drive circuit for driving an electric motor operating said window shade; a control circuit for controlling the operation of said drive circuit, said control circuit including a microprocessor,; first and second switches coupled to said microprocessor for enabling driving of said electric motor in respective first and second directions corresponding to upward and downward movement of said window shade, and a program switch; said microprocessor of said control circuit being programmed to allow setting of upper and lower limits of travel of said window shade, said microprocessor being programmed with a program whereby to set a first of said limits of travel, the window shade is adjusted to a desired upper or lower limit position using at least one of said first and second switches, said program switch is then actuated followed by the actuation of one of said first and second switches to set a first of said limits; said window shade is then adjusted to a desired position for a second of said limits using at least one of said first and second switches; said program switch is again actuated, and the other of said first and second switches is actuated to set said second of said limits.
 4. The apparatus of claim 3, wherein said first limit comprises an upper limit and said first switch comprises a switch for moving said window shade in an upward direction said second limit comprises a lower limit and said second switch comprises a switch for moving said window shade in a downward direction.
 5. A method for setting upper and lower limits of travel of a motorized window shade, said motorized window shade having a control circuit including a microprocessor for controlling the direction of movement of said window shade and having a first switch for allowing control of said window shade in an upward direction, a second switch for allowing control of said window shade in a downward direction and a program switch for enabling setting of said limits, the method comprising: adjusting said shade to a desired upper limit position using at least one of said first and second switches; actuating said program switch to command said microprocessor to a program mode; thereafter actuating said first switch to set said upper limit position to the current shade position; adjusting said window shade to a desired lower limit position using at least one of said first and second switches; actuating said program switch to command said microprocessor to said program mode; and thereafter actuating said second switch to set said lower limit position to the current position of said window shade.
 6. The method of claim 5, wherein said lower limit position is set prior to said upper limit position.
 7. The method of claim 5, further comprising providing a preset delay time after actuation of said program switch in which actuation of the first or second switches will be recognized by said microprocessor as a command to set the desired upper or lower limit position.
 8. Apparatus for detecting if a reelable window shade of a motorized window shade control system has exceeded a home position for said window shade, said apparatus comprising a drive circuit for driving an electric motor controlling upward and downward movement of said window shade; a control circuit including a microprocessor for controlling the operation of said drive circuit; a switch actuated by movement of said window shade when said window shade moves upwardly past said home position of said window shade; said microprocessor comprising a program operating in response to a change of state of said switch when said window shade is traveling upward so as to:stop the operation of said electric motor; reverse the direction of said electric motor; set a counter of said control circuit when said switch again changes state to a preset number corresponding to a home position of said window shade; and thereafter stop said motor when said window shade reaches a preset upper limit.
 9. A process for detecting when a window shade of a motorized window shade system has exceeded a home position, said window shade system including a drive circuit controlling an electric motor driving said window shade in upward and downward directions, a control circuit including a programmed microprocessor controlling the operation of said drive circuit and a switch activated when said window shade is traveling upwardly, the process comprising the steps of: changing the state of said switch when said shade is traveling upwardly and has exceeded said home position; stopping said motor; reversing the direction of said motor so that said window shade travels downwardly; setting a counter in said control circuit when said switch again changes state as said window shade is traveling downwardly; and thereafter stopping said motor when said shade reaches an upper limit.
 10. Apparatus for detecting when a window shade of a motorized window shade system has reached full downward extension and is beginning to wrap around a reel for said window shade in an opposite direction to a desired direction of wrap around said reel, said motorized window shade system comprising a drive circuit for driving an electric motor that moves said shade in upward and downward directions, a control circuit controlling the operation of said drive circuit and having a programmed microprocessor and a switch actuated by said window shade as said window shade is traveling downwardly and then begin to wrap around said reel in the opposite direction, said programmed microprocessor being programmed to detect the change of state of said switch by said window shade as said window shade is traveling downwardly, said programmed microprocessor being programmed to:respond to the change of state of said switch so as to stop said motor; reverse the direction of said motor so that said window shade travels upwardly changing the state of the switch until said window shade is fully wrapped around said window shade reel and another change of state of said switch by said shade occurs; stop said motor; reverse said motor direction so that said window shade travels downwardly; set a counter of said control circuit to a preset number corresponding to a home position of said window shade when a change of state of said switch again occurs; and stop said motor when said shade reaches a preset upper limit.
 11. A method for detecting when a window shade of a motorized window shade system has reached full downward extension and is beginning to wrap around a reel for said window shade in an opposite direction to a desired direction of wrap around said reel, said motorized window shade system comprising a drive circuit for driving an electric motor that moves said shade in upward and downward directions, a control circuit controlling the operation of said drive circuit and having a programmed microprocessor and a switch actuated by said window shade as said window shade is traveling downwardly and then begins to wrap around said reel in the opposite direction, said programmed microprocessor being programmed to detect the change of state of said switch by said window shade as said window shade is traveling downwardly, said programmed microprocessor being programmed to respond to the change of state of said switch, the method comprising:stopping said motor in response to actuation of said switch; reversing the direction of said motor so that said window shade travels upwardly changing the state of the switch until said window shade is fully wrapped around said window shade reel and another change of state of said switch by said shade occurs; stopping said motor; reversing said motor direction so that said window shade travels downwardly; setting a counter of said control circuit to a preset number corresponding to a home position of said window shade when a change of state of said switch again occurs; and stopping said motor when said shade reaches a preset upper limit. 